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Busy day today, but it was worth it.
Added 3 coats of paint to exhaust, dried in the sun a few hours and installed everything with new gaskets.
Put a two part epoxy on the crack in the gas tank patch weld. Seems to be holding.
Installed the rear drive shaft.
Tacked the tailpipe into place.
Fired the motor, let it get to temp to discover another coolant leak. Swapped out a tension clamp for a gear clamp.
Added 40 psi to all of the leaking tires.
Tour around the friggen block!!!!
Clutch is chattery, assuming it’s just breaking in. Forgot how amazing the brakes were. The fan clutch won’t release, so at 2500rpm i get belt squeal. The cherry bomb is toooo loud.
But this was a great first trip around the block.
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Welp, once again I underestimated the supplies I’d need, two cans of high temp paint were not enough. It didn’t spread nearly as far as I thought, barely got three coats laid using two cans. In hindsight, there’s a lot of surface area of all those individual fiber strands when you add it up. I ordered another two cans to arrive by Monday. Grrr.
Last night I ran Redee in the shop with the full exhaust in place to help burn in, cure and dry the Fiberglass and bbq paint. Redee ran awesome with no engine lights, so the O2s are still working just fine. Had a lovely idle between 700-800 rpm, no strange noises, and the exhaust sounds good and is pretty tame at idle. I didn’t rev it at all, was midnight, and hardly any gas in the tank.
Speaking of the fuel tank, I bought a permeatex brand two part epoxy to apply to the outside, hopefully stop that leak. On the outside of the package, it clearly says “sticks to fuel soaked metal” on the package, so I’m optimistic it’ll hold, but will it seal…. Time will tell.
Yesterday after dinner I checked my mailbox, to my surprise the last of my Fiberglass wrap was inside! So 10 mins after I tucked the kids in, it to the shop to finish wrapping the header and catalytic pipe. I’m not too happy with how the first 6″ of the catalytic pipe turned out, but it’ll never be seen by anybody but me (and you fine folks on the internet), so I’ve come to terms with said ugliness.
Up next, more drying and then many coats of high temp silicone paint to seal it up.
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Well I used up 95% of the Fiberglass wrap in my hoard of parts, waiting on ebay to deliver the last of what I need. I had enough to wrap 85% off the header, and lemme tell you that was a pain. I did manage to avoid the Fiberglass itch, so that’s yet another win.
I’ll finish wrapping the last two pipes of the header, then the catalytic pipe when the last of the material arrives. Any day now really.
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New addition.
1985 4Runner, 22R-E w/ 340,000kms, W56, bone stock, clean interior, bad body work, and flat suspension.
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Getting suuuper close.
1: wrap and seal exhaust. Bolt in.
2: rear diff swap (4:10 ARB to 4:88 lunchbox)
3: rear driveshaft install
4: new (or used if possible) tires
5: Test driveTechnically I could skip #2 & #4 to get the test drive out the way, pretty tempted to do so. Time will tell.
All done welding. Until I finalize the tailpipe angle and set that with lightning.
It all came out, got bolted together for a cool picture, then immediately unbolted so it could be painted and look even cooler in the next pictures. But mainly to slow down surface rust. Just high temp bbq paint, very little prep done. Solong red and rust coloured cherry bomb, hello brand new special edition matte black Cherry bomb.
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My buddy hooked me up with some custom grind parts from his down time at work, many thanks Matt.
Looking forward to welding these in tonight and calling an end to exhaust fabrication. Just arts and crafts will remain
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Well here it is, approximately 11 linear feet of custom exhaust. My kit was $184, and in total I used 7 of the 16 pieces in the kit. Not much scrap at all.
I only need to weld in my O2 flanges after they get contoured a bit. I was planning to do that at work today, but I left after 1 hour to take care of my sick family. I left the task with a buddy, for if he had downtime. Odds are he did. Will find out tomorrow.
I can snake the catalytic pipe into with the O2 sensors in place, means I don’t have to fiddle with nuts, just clips.Attachments:
Another long night of welding, but the exhaust is nearly finished now.
All that’s left for fabrication is to add the two O2 ports, and the flange union behind the tcase. After I add the union, I’ll finish weld the last piece of the tailpipe. But currently, it’s welded and hanging on two rubber isolators.Im motivated to wrap the front section so I can let the motor warm up without melting stuff. A few seconds is the longest Ive ran the motor with the exhaust in place.
Another great day of progress
Much happier with the fit now that I added a 7″ run in the 45* bend, raised everything about 2″. The weld is quite ugly, but I’m tired and it’s strong enough.
Next time up I’ll start on the tailpipe.
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Did a little more welding today, still need to add the flanges. I want to cut a section I already made, and add a 2″ spacer to bring everything closer to the floor. I am trying to decide if it’s worth it or not, I’ll chew on it a bit longer.
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Got a little more of the exhaust built today, not bad for pre-lunch progress!
Fired up Redee, sounds pretty mean (AND LOUD!!) through the Cherry bomb. I will ensure the tailpipe clears the body to prevent interior drone. Will aim to exit the tailpipe in the OEM location behind the rear tire
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Yea these things definitely predate Safety. I think once I’ve used my model 518 heater, as an adult, in Ardbeg in October. For sure it helped cut the cold, glad I didn’t go up in flames.
Last night I stayed up late fabricating some of the exhaust. I have nearly finished the first pipe with catalytic converter, it started after the header and will finish behind the T-case with a two-bolt flange. Thus far (without the flange) I can easily twist this piece into place above the crossmember and beside tcase. I can get my hand around the pipe everywhere.
To finish this pipe I need to add the flange, and a pair of O2 flanges. I still have to grind the O2 flanges to contour their shape, gonna do it at work on the belt sander. The whole thing will get painted and wrapped in Fiberglass.The next piece will go from the tcase to back of the muffler. Might be my goal for tonight.
